JPH09123584A - Particle pattern decorative sheet and manufacture of formed item with grain pattern employing this - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a grain pattern decorative sheet for forming particle patterns with an excellent three dimensional effect, and a manufacture of a formed item with particle pattern employing this. SOLUTION: A polyvinyl chloride film of a thickness of 200μm is employed as a white turbid plastic sheet 2 with a haze of 5.0, and gravure printing is carried out on its surface by the use of an ink with carbon black as a pigment contained in a binder consisting of polyvinyl chloride resin to form first grain pattern layers 3 of conduit patterns. Also, on the rear surface of the white turbid plastic sheet 2, gravure printing is carried out by the use of the ink with carbon black as a pigment contained in a binder consisting of polyvinyl chloride to form second particle pattern layers 4 of fiber patterns having a brightness of 1, subsequently, gravure printing is executed with the use of ink with red iron oxide as a pigment contained in a binder consisting of polyvinyl chloride resin to form a masking mat layer on the entire surface thereof.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to furniture, furniture,
A wood grain pattern decorative sheet used for imparting a wood grain pattern with an excellent three-dimensional effect to molded products such as wall materials, surface materials for home appliances and interior materials for automobiles, and a method for producing molded products with a wood grain pattern using the same Regarding

[0002]

2. Description of the Related Art Conventionally, as a surface material for furniture, an interior material for automobiles, etc., a wood grain decorative sheet in which a wood grain pattern is printed on a base sheet is directly attached to the surface of a molded product such as plywood, particle board or resin molding. Alternatively, when the molded product is a resin, it may be bonded at the same time as injection molding.

Since the above-mentioned wood grain decorative sheet has a drawback in that it is difficult to obtain an appearance similar to the actual natural wood surface by simply printing the wood grain pattern, a transparent plastic sheet is used as the base sheet. It has been practiced to separately provide a first wood grain pattern layer and a second wood grain pattern layer on the front and back surfaces. In other words, the difference in the sense of distance between the two types of wood grain patterns gives the wood grain a three-dimensional effect.

[0004]

However, in actuality, the difference in the sense of distance cannot be felt between the two types of wood grain patterns when the thickness is about the same as the transparent plastic sheet used as the base sheet of the wood grain pattern decorative sheet, so that the wood grain pattern has no difference in distance. I couldn't really get the stereoscopic effect. The thickness of the transparent plastic sheet must be at least a few millimeters to give the wood grain a three-dimensional effect, which is not suitable as a wood grain decorative sheet.

Accordingly, the present invention solves the above problems and provides a wood grain pattern decorative sheet for forming a wood grain pattern having an excellent three-dimensional effect, and a method for producing a molded product with a wood grain pattern using the same. To aim.

[0006]

[Means for Solving the Problems] In order to achieve the above object, the wood grain decorative sheet of the present invention has a haze value of 1.3 to 20.
The first grain pattern layer was formed on the surface of the cloudy plastic sheet of No. 0, and the second grain pattern layer and the concealing solid layer were sequentially formed on the back surface of the cloudy plastic sheet.

In the above structure, the haze value of the cloudy plastic sheet is set to 2-5.

In the above construction, the lightness of the color of the second wood grain pattern layer is set to 4 or less.

In the above structure, a surface protective layer is formed on the surface of the cloudy plastic sheet so as to cover the first wood grain pattern layer.

In the above structure, an adhesive layer is formed on the back surface of the concealing solid layer.

The method for producing a molded product with a wood grain pattern of the present invention is as follows:
Each of the above wood grain decorative sheets was configured to be directly attached to the surface of the molded product.

In the method for producing a molded product with a wood grain pattern of the present invention, the wood grain pattern decorative sheet is used, and the wood grain pattern is arranged so that the first wood grain pattern layer side of the wood grain pattern decorative sheet and the inner wall surface of the mold are in contact with each other. Place the decorative sheet in the mold for injection molding, close the mold, inject the molten resin to mold the molded product, and at the same time,
The wood grain pattern decorative sheet may be adhered to the surface of the molded product by heat and pressure of the injected molten resin.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail below with reference to the drawings. 1 to 3 are cross-sectional views showing an embodiment of the wood grain pattern decorative sheet of the present invention, and FIGS. 4 and 5 are cross-sectional views showing one step of the method for producing a molded product with a wood grain pattern of the present invention. In the figure, 1 is a wood grain decorative sheet, 2 is a cloudy plastic sheet, 3 is a first wood grain pattern layer, 4 is a second wood grain pattern layer, 5 is a concealing solid layer, 6 is a surface protective layer, 7 is an adhesive layer, 8 Is a molded product with a grain pattern, 9 is a molded product, 10 is an adhesive, 11 is a mold,
Reference numeral 12 denotes a molten resin, respectively.

The wood grain decorative sheet 1 shown in FIG. 1 has a haze value of 1.
The first grain pattern layer 3 is formed on the surface of the cloudy plastic sheet 2 of 3 to 20.0, and the second grain pattern layer 4 and the concealing solid layer 5 are sequentially formed on the back surface of the cloudy plastic sheet 2.

As the cloudy plastic sheet 2, a plastic sheet having a haze value of 1.3 to 20.0 is used. Haze (JIS K 6900) refers to the unclear cloudy appearance of the inside or surface of transparent plastic, and the haze value is a numerical value indicating the degree of this haze. The ratio between the diffuse transmitted light amount and the total transmitted light amount of is shown as a percentage. A low haze value indicates low cloudiness and high transparency, while a high haze value indicates cloudiness and low transparency.

According to the present invention, by using the cloudy plastic sheet 2, the second wood grain layer 4 seen through the cloudy plastic sheet 2 is blurred from the first grain pattern layer 3. Due to this difference in sharpness, the two types of wood grain patterns are felt to be more distant than the actual distance between the two types, so that it is possible to form a wood grain pattern having a three-dimensional effect superior to that of the prior art. However, if the haze value exceeds 20.0, there is a problem that the second wood grain pattern layer provided on the back surface of the cloudy plastic sheet 2 becomes difficult to understand, and the haze value is
If the ratio is less than 1.3, there is a problem that the difference in sharpness between the first grain pattern layer and the second grain pattern layer seen through the cloudy plastic sheet 2 cannot be visually recognized. Limited to the range of 20.0. Particularly, a haze value of 2 to 5 is preferable. A particularly preferable range is 1.3 to 20.0 in the range of haze value 1.3 to 20.0.
May be perceived as biased to the side, but not really. This is because the difference of 0.1 on the low haze side affects the recognition of the second wood grain layer much more than the same difference of 0.1 on the high haze side.

As the cloudy plastic sheet 2 having a haze value of 1.3 to 20.0, for example, those having the materials and thicknesses shown in Table 1 can be used.

[0018]

[Table 1]

The first wood grain pattern layer 3 is a layer for expressing the pattern which is desired to be projected in the front among the wood grains such as annual rings, fibers and conduits which appear at the cut end of the tree. It should be noted that there is no rule as to which pattern among the wood patterns of the conduit or the like is the first wood pattern pattern layer 3 and the other patterns are the second wood pattern pattern layer 4, and may be distributed to each layer in any manner. The first wood grain pattern layer 3 includes polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin, polyamide resin, cellulose resin, polyester resin, polyacetate vinyl resin, polyethylene resin, polycarbonate resin, polystyrene resin. A material containing a melamine resin and a copolymer thereof as a binder and a dye / pigment as a coloring material can be used, and a single color or a plurality of colors are selected from colors such as black, orange, red, and yellow. As the dye / pigment, for example, carbon black, benzidine orange, red iron oxide, toluidine red, fast yellow, and watching red can be used. The first wood grain pattern layer 3 is formed by a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method. In addition, a coating method such as a roll coating method or a spray coating method is used for masking.

The second wood grain pattern layer 4 is a layer for expressing a pattern to be retracted rearward among the wood grains such as annual rings, fibers and conduits appearing at the cut end of the tree. As the second wood grain pattern layer 4, the one made of the same binder and coloring material as the first wood grain pattern layer 3 can be used. The method for forming the second wood grain pattern layer 4 is the same as that for the first wood grain pattern layer 3.

The present invention also makes the second grain pattern layer 4 unclear by looking through the cloudy plastic sheet 2. However, if the lightness of the color of the second wood grain pattern layer 4 is high, the impression that the second wood grain pattern layer 4 is unclear is weakened, and the two types of wood grain patterns are farther apart than the actual distance between them. It is hard to feel like. Therefore, the second wood grain pattern layer 4 in the present invention preferably has a color lightness of 4 or less. The brightness is the “brightness” of the perceived color on the surface of the object, and is a scale of the attribute of visual perception that determines whether the luminous reflectance is large or small. In the present invention, the lightness according to the Munsell color system, that is, Munsell value (JIS Z 8105) is used. To express the lightness, ideal black is V = 0 and ideal white is V = 10, and the interval is divided into ten.

The concealed solid layer 5 is a layer expressing a basic color tone other than the grain appearing at the cut end of the tree. As the concealing solid layer 5, there are polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin, polyamide resin, cellulose resin, polyester resin, polyvinyl acetate resin, polyethylene resin, polycarbonate resin, polystyrene resin, melamine. It is possible to use those containing a resin and a copolymer thereof as a binder and a dye / pigment as a coloring material, orange, red, yellow, blue, green,
Choose from colors such as white. As the dye / pigment, for example, benzidine orange, red iron oxide, titanium dioxide, brilliant carmine, lake red, fast yellow, phthalocyan blue, phthalocyan green and the like can be used. As the method for forming the concealed solid layer 5, a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, or a coating method such as a roll coating method or a spray coating method is used.

Although the wood grain decorative sheet 1 of FIG. 1 has been described above, the present invention is not limited to the above embodiment. For example, the surface protective layer 6 may be formed on the surface of the cloudy plastic sheet 2 so as to cover the first wood grain pattern layer 3 (see FIG. 2). The surface protection layer 6 is a layer provided for surface protection and polishing of the first wood grain pattern layer 3.
Generally, when the first wood grain pattern layer 3 contains a coarse pigment, fine irregularities are generated on the surface of the first wood grain pattern layer 3 by the pigment, and thus the fine irregularities cause irregular reflection of light and the first wood grain pattern layer 3
Deluster. In this case, the first wood grain pattern layer 3 becomes unclear due to matting, and the difference in sharpness from the second wood grain pattern layer 4 seen through the cloudy plastic sheet 2 is relatively small. Therefore, by providing the surface protective layer 6 on the first wood grain pattern layer 3, the diffuse reflection of light is suppressed and the first wood grain pattern layer 3 is glossed,
The effect of the present invention due to the difference in sharpness between the first wood grain pattern layer 3 and the second wood grain pattern layer 4 seen through the cloudy plastic sheet 2 can be further exerted.

The surface protective layer 6 is a surface protective ink coating layer or a surface protective sheet. As the surface protection ink coating layer and surface protection sheet, acrylic resin, urethane resin, polyester resin,
A resin made of polyvinyl chloride resin, a mixture of fluororesin and acrylic resin, nitrocellulose, cellulose acetate, chlorinated polypropylene, or the like can be used. As a method for coating the surface protection ink, a coating method such as a roll coating method or a spray coating method is used. A laminating method or the like is used as a method for forming the surface protection sheet. The surface protection layer 6 has a haze value of 1.5.
It is preferable that the haze value is below and is relatively lower than that of the cloudy plastic sheet 2. Because, the first wood grain pattern layer 3
This is because the effect of the present invention is diminished when the surface protective layer 6 becomes cloudy and becomes unclear. Haze value
As the surface protection ink coating layer having a thickness of 1.5 or less, for example, those having the materials and thicknesses shown in Table 2 can be used.

[0025]

[Table 2]

As the surface protective sheet having a haze value of 1.5 or less, for example, those having the materials and thicknesses shown in Table 3 can be used. It may be accepted that the thickness of the surface protective sheet having a haze value of 1.5 or less is not so different from the thickness of the cloudy plastic sheet 2 having a haze value of 1.3 to 20.0. There is a reason. This is because the change in sheet thickness required to make a difference of 0.1 on the low haze side is much larger than the change in sheet thickness required to make the same difference of 0.1 on the high haze value side.

[0027]

[Table 3]

An adhesive layer 7 may be formed on the back surface of the concealing solid layer 5 (see FIG. 3). The adhesive layer 7 is a layer for adhering the wood grain decorative sheet 1 of the present invention to a molded product such as plywood, particle board, and resin molded body. As the adhesive layer 7, polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin,
Polyamide resin, polyester resin, polyvinyl acetate resin, polyethylene resin, etc. are used. As a method of forming the adhesive layer 7, a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexo printing method, or the like,
A coating method such as a roll coating method or a spray coating method is used.

The wood grain decorative sheet 1 of the present invention may have a gloss layer as one constituent layer (not shown). The gloss layer is
It is a layer that expresses the unique luster of wood, and is formed wholly or partially. As the gloss layer, polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin, polyamide resin, cellulose resin, polyester resin, polyacetic acid vinyl resin, polyethylene resin, polycarbonate resin, polystyrene resin,
A melamine resin and a copolymer thereof may be used as a binder, and those containing a bright pigment may be used.
Examples of bright pigments include pearl pigments and metal powders of copper, aluminum, gold, silver and the like having a particle size of 150 μm or less. Also, as a gloss layer, aluminum, chrome,
It is also possible to use a metal thin film such as tin or copper. As a method for forming a glossy layer containing a bright pigment, an ordinary printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, or a coating method such as a roll coating method or a spray coating method is used. . On the other hand, as a method for forming the glossy layer formed of a metal thin film, there are a vacuum vapor deposition method, an ion plating method, a sputtering method, and a metal foil attachment.

The bright pigment may be added to the first wood grain pattern layer 3 or the second wood grain pattern layer 4.

In the wood grain decorative sheet 1 of the present invention, the anchor layer may be a constituent layer (not shown). The anchor layer is a layer that improves adhesion between any of the above layers. As the anchor layer, polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin, polyamide resin, cellulose resin, polyester resin, polyvinyl acetate resin,
Polyethylene resin, polycarbonate resin, polystyrene resin, melamine resin and copolymers thereof are used. As a method of forming the anchor layer, a usual printing method such as an offset printing method, a gravure printing method, a screen printing method, a flexographic printing method, or a coating method such as a roll coating method or a spray coating method is used.

Hereinafter, a method of manufacturing a molded product with a wood grain pattern using the wood grain pattern decorative sheet 1 will be described.

As a method of manufacturing the molded product 8 with a wood grain pattern of the present invention, there is a method in which the decorative sheet 1 with a wood grain pattern is directly attached to the surface of the molded product 9. Examples of the material of the molded product 9 include plywood, particle board, and resin molded body. To attach the wood grain decorative sheet 1 to the molded product 9, usually, the adhesive 10 is applied to the concealed solid layer 5 of the wood grain decorative sheet 1 or the molded product 9.
Then, the wood grain decorative sheet 1 is superposed on the molded product 9 and pressed from above the wood grain decorative sheet 1 using a rubber roll, a silicone pad or the like (FIG. 4). As the adhesive, polyurethane resin, acrylic resin, polyvinyl chloride resin, epoxy resin, chlorinated polypropylene resin, polyamide resin, polyester resin, polyvinyl acetate resin,
Polyethylene resin or the like is used.

However, when the wood grain decorative sheet 1 has the adhesive layer 7, it is not necessary to apply the adhesive 10, and the wood grain decorative sheet 1 is superposed on the molded product 9 and heated rubber roll or silicone. Molded product 8 with wood pattern by heating and pressing from above the wood pattern decorative sheet 1 using a pad or the like.
Get.

When the molded product 9 is a resin molded product, the molded product 9 with a grain pattern can be obtained at the same time when the molded product 9 is molded. That is, using the wood grain pattern decorative sheet 1,
The wood grain pattern decorative sheet 1 is placed in the mold 11 for injection molding so that the first wood grain pattern layer 3 side of the wood grain pattern decorative sheet 1 and the inner wall surface of the mold 11 are in contact with each other, and the mold is closed. 12 is injected to mold the molded product 9, and at the same time, the heat and pressure of the injected molten resin 12 adhere the wood grain decorative sheet 1 to the surface of the molded product 9 (FIG. 5). Examples of the molten resin 12 to be injected include polycarbonate resin, acrylic resin, acrylonitrile butadiene styrene copolymer resin, acrylonitrile styrene copolymer resin, and styrene copolymer resin. Before performing the injection molding, the wood grain pattern decorative sheet 1 may be preformed so that it easily conforms to the shape of the inner wall surface of the mold 11. Examples of the preforming method include vacuum forming, pressure forming, and press forming. The preforming may be performed before the wood grain pattern decorative sheet 1 is placed in the injection molding die 11 using the preforming die, or the injection molding die 11 may be used. Using wood grain decorative sheet 1
It may be performed after placing in the mold 11.

[0036]

【Example】

Example 1 A 200 μm thick vinyl chloride film was used as a haze 5.0 cloudy plastic sheet. The first wood grain pattern layer (binder: pigment = 6: 4) of the conduit pattern is formed on the surface of the cloudy plastic sheet by gravure printing using an ink containing carbon black as a pigment in a binder made of polyvinyl chloride resin. Then, a 125 μm thick methyl methacrylate film was laminated so as to cover the first wood grain pattern layer to form a surface protective layer of haze 1.3. On the back surface of the cloudy plastic sheet, a second wood grain pattern layer (binder: pigment = 6) with a lightness of 1 was obtained by gravure printing using an ink containing carbon black as a pigment in a binder made of polyvinyl chloride resin. : 4), and then gravure printing using an ink containing red iron oxide as a pigment in a binder made of polyvinyl chloride resin to form a concealing solid layer (binder: pigment = 6: 4) on the entire surface. Then, an adhesive layer made of epoxy resin was formed on the entire surface.

The above wood grain decorative sheet is overlaid on a particle board and heated from above the wood grain decorative sheet 1 using a silicon pad or the like for 3 hours at 100 to 200 ° C. and a pressure of 50 g / cm ² . Then, a molded product with a grain pattern was obtained.

The molded product with a wood grain pattern thus obtained was excellent in three-dimensional effect because the conduit pattern was more prominent than the fiber pattern.

Example 2 A 200 μm thick methyl methacrylate film was used for haze 2.5.
Was used as a cloudy plastic sheet. The first wood grain pattern layer (binder: pigment = 6: 4) of the conduit pattern is formed on the surface of the cloudy plastic sheet by gravure printing using an ink containing carbon black as a pigment in a binder made of polyvinyl chloride resin. Then, a 10 μm thick thermoplastic acrylic resin was laminated so as to cover the first wood grain pattern layer to form a surface protective layer of haze 1.1. On the back surface of the cloudy plastic sheet, a second wood grain pattern layer (binder: pigment = 6) with a lightness of 1 was obtained by gravure printing using an ink containing carbon black as a pigment in a binder made of polyvinyl chloride resin. : 4) and then gravure printing using an ink containing red iron oxide as a pigment in a binder made of polyvinyl chloride resin to form a concealing solid layer (binder: pigment = 6: 4) on the entire surface,
Finally, an adhesive layer made of epoxy resin was formed on the entire surface.

Using the above wood grain decorative sheet, the wood grain decorative sheet was placed in a mold for injection molding so that the surface protective layer side of the wood grain decorative sheet was in contact with the inner wall surface of the mold, and the mold was closed. After that, melted 220-250 ℃ acrylonitrile butadiene polystyrene copolymer resin is injected into the mold of 40-60 ℃ to mold the molded product, and at the same time, heat and injection pressure of the injected melted resin make the wood grain pattern makeup. The sheet was adhered to the surface of the molded product to obtain a molded product with a grain pattern.

The molded product with a wood grain pattern thus obtained was excellent in three-dimensional appearance because the conduit pattern was more prominent than the fiber pattern.

[0042]

EFFECTS OF THE INVENTION A wood grain pattern decorative sheet and a method for producing a molded product with a wood grain pattern using the same include a first wood grain pattern layer and a second wood grain pattern layer on the front and back surfaces of a cloudy plastic sheet having a haze value of 1.3 to 20.0. Since it is formed separately, the second wood grain pattern layer seen through the cloudy plastic sheet is less clear than the first wood grain pattern layer. Therefore, because of the difference in sharpness, the two types of woodgrain patterns are felt to be farther apart from each other than the actual distance between them, so that a woodgrain pattern having a three-dimensional effect superior to that of the prior art can be formed.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a wood grain decorative sheet of the present invention.

FIG. 2 is a cross-sectional view showing an example of a wood grain decorative sheet of the present invention.

FIG. 3 is a cross-sectional view showing an example of a wood grain decorative sheet of the present invention.

FIG. 4 is a cross-sectional view showing a step in the method for producing a molded product with a wood grain pattern of the present invention.

FIG. 5 is a cross-sectional view showing one step of a method for producing a molded product with a wood grain pattern of the present invention.

[Explanation of symbols]

 1 wood grain pattern decorative sheet 2 cloudy plastic sheet 3 first wood grain pattern layer 4 second wood grain pattern layer 5 concealing solid layer 6 surface protective layer 7 adhesive layer 8 wood grain patterned molded product 9 molded product 10 adhesive agent 11 mold 12 molten resin

Claims (7)

[Claims] 1. A first grain pattern layer is formed on the surface of a cloudy plastic sheet having a haze value of 1.3 to 20.0, and a second grain pattern layer and a concealing solid layer are sequentially formed on the back surface of the cloudy plastic sheet. A wood grain decorative sheet. 2. The haze value of the cloudy plastic sheet is 2.
The grain-patterned decorative sheet according to claim 1, which is -5. 3. The wood grain decorative sheet according to claim 1, wherein the second wood grain layer has a color lightness of 4 or less. 4. A surface protective layer is formed on the surface of the cloudy plastic sheet so as to cover the first wood grain pattern layer.
A wood grain decorative sheet according to any one of claims 3 to 4. 5. The wood grain decorative sheet according to any one of claims 1 to 4, wherein an adhesive layer is formed on the back surface of the concealing solid layer. 6. A method for producing a molded product with a wood pattern, wherein the wood pattern decorative sheet according to any one of claims 1 to 5 is directly attached to the surface of the molded product. 7. The wood grain decorative sheet using the wood grain decorative sheet according to claim 1, wherein the first wood grain layer side of the wood grain decorative sheet and the inner wall surface of the mold are in contact with each other. Is placed in a mold for injection molding, the mold is closed, then molten resin is injected to mold the molded product, and at the same time the heat and pressure of the injected molten resin bond the wood pattern decorative sheet to the surface of the molded product. A method for producing a molded product with a wood grain pattern, which comprises: